Power and home tools

ABSTRACT

A hand-held tool that includes a housing. The housing includes a handle. A tool also includes a motor assembly, a battery assembly and a circuit board. The motor assembly includes a motor, the motor including a rotatable motor output shaft, a motor positive terminal and a motor negative terminal. The motor assembly also includes a first rigid conductive electrical connector having a first end fixed to the motor positive terminal and a second end fixed to the circuit board. The battery assembly includes a battery cell with a battery cell positive terminal and a battery cell negative terminal. The battery assembly further includes a second rigid conductive electrical connector having a first end fixed to the battery cell positive terminal and a second end fixed to the circuit board.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. patentapplication Ser. No. 15/887,209 filed on Feb. 2, 2018, which claims thebenefit of U.S. Provisional Application No. 62/622,378 filed on Jan. 26,2018, entitled Power and Home Tools; and U.S. Provisional ApplicationNo. 62/609,012 filed on Dec. 21, 2017; and U.S. Provisional ApplicationNo. 62/459,333 filed on Feb. 15, 2017. The entire contents of all areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to simplified design of tools. The toolsmay include a home tool, such as a cordless vacuum, or a power tool,such as a screwdriver. The simplified design may lend itself toautomated manufacturing.

BACKGROUND

There are various existing tools. It is desired to provide tools with asimplified design which may provide a simplified assembly.

SUMMARY

According to an aspect of an exemplary embodiment, there is ascrewdriver and charger system. The screwdriver and charger systemincludes a charger and a screwdriver. The charger includes at least onecell monitor which monitors a voltage of a battery and configured toprovide a charging current to the battery. The screwdriver includes ahousing, the battery housed in the housing, a motor housed in thehousing and a rotatable spindle driven by the motor and configured tohold and drive a bit.

The least one cell monitor may include two cell monitors.

The charger may further include an independent charge shut-off.

The charger may include a circuit board.

The at least one cell monitor may be mounted on the circuit board.

The independent charge shut-off may be mounted on the circuit board.

The screwdriver may not include any printed circuit boards.

The screwdriver may not include any cell monitors.

The screwdriver may not include an independent charge shut-off.

The screwdriver may include a user-actuatable switch.

The switch may include a stamped metal connector.

Actuating the switch may connect the stamped metal connector on theswitch to stamped metal connectors in the screwdriver housing tocomplete a circuit and provide power from the battery to the motor.

According to another aspect, there is an exemplary embodiment of ascrewdriver. The screwdriver includes a housing, a battery housed in thehousing, a motor housed in the housing and a rotatable spindle driven bythe motor and configured to hold and drive a bit. An electricalconnection between the battery and the motor for powering the motor bythe battery is provided through a circuit board.

The screwdriver may further include a light and power from the batteryto the light for powering the light is provided through the circuitboard.

The screwdriver may further include a light and power from the batteryto the light for powering the light is provided through a second circuitboard.

The battery may be soldered to the circuit board.

The motor may be soldered to the circuit board.

The battery may be connected to the circuit board by tulip clips.

The motor may be connected to the circuit board by tulip clips.

The battery may be connected to the circuit board in an insertionmethod.

The motor may be connected to the circuit board by an insertion method.

The screwdriver may have a housing and the battery may be placed in thehousing and the circuit board slid into connection with the batterywhile the battery is in the housing.

The screwdriver may have a housing and the motor may be placed in thehousing and the circuit board slid into connection with the batterywhile the motor is in the housing.

The screwdriver may have a housing and the battery and motor may beplaced in the housing and the circuit board slid into connection withthe battery and motor while the battery and motor are in the housing.

The screwdriver may have a housing and the battery may be connected tothe circuit board and then the battery and circuit board together areinserted into the housing.

The screwdriver may have a housing and the motor may be connected to thecircuit board and then the motor and circuit board together are insertedinto the housing.

The screwdriver may have a housing and the battery and motor may beconnected to the circuit board and then the battery, motor and circuitboard together are inserted into the housing.

The connection between the battery and the motor may be made withoutwires.

The connection between the battery and the motor may be made by enameledwires.

The connection between the battery and the motor may be made byuninsulated wires.

According to another aspect, there is an exemplary embodiment of ahand-held vacuum cleaner. The hand-held vacuum cleaner includes ahousing and a motor, a fan driven by the motor and a battery whichpowers the motor housed in the housing. The fan creates suction fordrawing dirt into a canister.

The housing may not contain a circuit board.

The battery may be electrically connected to the motor via enameledwires.

The battery may be electrically connected to the motor via uninsulatedwires.

The housing may house two or more batteries which are connected to andpower the motor.

The battery may be connected to the motor via a circuit board.

The hand vac may include a switch for activating the motor.

The switch may include two stamped metal connectors which connect toform a circuit and provide power from the battery to the motor.

The switch may include a stamped metal connector disposed between thepositive terminal of the battery pack and a positive terminal of themotor, the stamped metal connector may be movable between a positionwhere it provides an electrical path between the positive terminal ofthe battery pack and a positive terminal of the motor and a positionwhere it does not provide an electrical path between the positiveterminal of the battery pack and a positive terminal of the motor.

According to another aspect, there is an exemplary embodiment of a handvac and charger system. The hand vac and charger system includes acharger and a hand vac. The charger includes at least one cell monitorwhich monitors a voltage of a battery and configured to provide acharging current to the battery. The hand vac includes a housing, thebattery housed in the housing, a motor housed in the housing and arotatable spindle driven by the motor and configured to hold and drive abit.

According to another aspect, there is an exemplary embodiment of a handheld portable power tool with an integral battery and charger system.The power tool and charger system includes a charger and a power tool.The charger includes at least one cell monitor which monitors a voltageof a battery and configured to provide a charging current to thebattery. The power tool includes a housing, the battery housed in thehousing, a motor housed in the housing and an output driven by themotor.

The integral battery may include one battery cell.

The integral battery may include two battery cells.

The integral battery may be a lithium-ion battery.

The integral battery may have a nominal voltage of approximately 3.6 to4 volts.

The integral battery may have a nominal voltage of approximately 7.2 to8 volts.

The integral battery may have a nominal voltage of 9 volts or less.

The integral battery may have a nominal voltage of 8 volts or less.

The least one cell monitor may include two cell monitors.

The charger may further include an independent charge shut-off.

The charger may include a circuit board.

The at least one cell monitor may be mounted on the circuit board.

The independent charge shut-off may be mounted on the circuit board.

The power tool may not include any printed circuit boards.

The power tool may not include any cell monitors.

The power tool may not include an independent charge shut-off.

The power tool may include a user-actuatable switch.

The switch may include a stamped metal connector.

Actuating the switch may connect the stamped metal connector on theswitch to stamped metal connectors in the screwdriver housing tocomplete a circuit and provide power from the battery to the motor.

According to another aspect, there is an exemplary embodiment a handheld portable power tool with an integral battery. The power toolincludes a housing, a battery housed in the housing, a motor housed inthe housing and a rotatable spindle driven by the motor and configuredto hold and drive a bit. An electrical connection between the batteryand the motor for powering the motor by the battery is provided througha circuit board.

The battery may have a nominal voltage of 9 volts or less and mayinclude one or more battery cells.

The battery may be soldered to the circuit board.

The motor may be soldered to the circuit board.

The battery may be connected to the circuit board by tulip clips.

The motor may be connected to the circuit board by tulip clips.

The battery may be connected to the circuit board in an insertionmethod.

The motor may be connected to the circuit board by an insertion method.

The power tool may have a housing and the battery may be placed in thehousing and the circuit board slid into connection with the batterywhile the battery is in the housing.

The power tool may have a housing and the motor may be placed in thehousing and the circuit board slid into connection with the batterywhile the motor is in the housing.

The power tool may have a housing and the battery and motor may beplaced in the housing and the circuit board slid into connection withthe battery and motor while the battery and motor are in the housing.

The power tool may have a housing and the battery may be connected tothe circuit board and then the battery and circuit board together areinserted into the housing.

The power tool may have a housing and the motor may be connected to thecircuit board and then the motor and circuit board together are insertedinto the housing.

The power tool may have a housing and the battery and motor may beconnected to the circuit board and then the battery, motor and circuitboard together are inserted into the housing.

The connection between the battery and the motor may be made withoutwires.

The connection between the battery and the motor may be made by enameledwires.

The connection between the battery and the motor may be made byuninsulated wires.

According to another aspect, there is an exemplary embodiment of ahand-held drill or screwdriver. The drill or screwdriver includes ahousing; a motor assembly held in the housing; a battery assembly heldin the housing; and a circuit board adjacent to the battery assembly andthe motor assembly. The motor and the battery assembly are electricallyconnected to the circuit board.

The battery assembly may include a battery and an electrical connecter.

The electrical connector may extend from a terminal of the battery tothe circuit board.

The electrical connector may be soldered to the circuit board.

The motor assembly may include a motor and an electrical connector.

The electrical connector may extend from a terminal of the motor to thecircuit board.

The electrical connector may be soldered to the circuit board.

There may be two electrical connectors extending from that battery tothe circuit board, one connected to a positive terminal of the batteryand one connected to the negative terminal of the battery. Eachelectrical connector may be electrically connected to the circuit boardby, for example, soldering. There may be multiple batteries connected tothe circuit board in this manner.

There may be two electrical connectors extending from the motor to thecircuit board, one connected to a positive terminal of the motor and oneconnected to the negative terminal of the motor. Each electricalconnector may be electrically connected to the circuit board by, forexample, soldering.

The screwdriver or drill may have a chuck. The drill or screwdriver mayhave a transmission. The drill or screwdriver may have an outputspindle. The drill or screwdriver may have a bit holder, such as ahexagonal bit holder.

The circuit board may dispose at an angle with respect to the battery.

The angle may be more than 5 degrees.

The angle may be more than 10 degrees.

The angle may be more than 20 degrees.

The angle may be more than 25 degrees.

The circuit board may be disposed at an angle with respect to the motor.

The angle may be more than 5 degrees.

The angle may be more than 10 degrees.

The angle may be more than 20 degrees.

The angle may be more than 25 degrees.

The circuit board may be generally flat and lie in a plane.

The motor may have a longitudinal axis.

The battery may have a longitudinal axis.

The longitudinal axis of the motor may be parallel to the longitudinalaxis of the battery.

The plane may be disposed at an angle with respect to the longitudinalaxis of the battery and the longitudinal axis of the motor.

The angle may be greater than 5 degrees.

The angle may be greater than 10 degrees.

The angle may be greater than 15 degrees.

The angle may be greater than 20 degrees.

The angle may be greater than 25 degrees.

The hand-held powered tool may be a vacuum cleaner. The vacuum cleanermay include a fan. The vacuum cleaner may include a canister.

According to another aspect, there is a hand-held powered tool,including a housing; a motor assembly held in the housing; a batteryassembly held in the housing; and a circuit board adjacent to thebattery assembly and the motor assembly. The motor and the batteryassembly are electrically connected to the circuit board.

The battery assembly may include a battery and an electrical connecter.

The electrical connector may extend from a terminal of the battery tothe circuit board.

The electrical connector may be soldered to the circuit board.

The motor assembly may include a motor and an electrical connector.

The electrical connector may extend from a terminal of the motor to thecircuit board.

The electrical connector may be soldered to the circuit board.

The circuit board may be disposed at an angle with respect to thebattery.

The angle may be more than 5 degrees.

The angle may be more than 10 degrees.

The angle may be more than 20 degrees.

The angle may be more than 25 degrees.

The circuit board may be disposed at an angle with respect to the motor.

The angle may be more than 5 degrees.

The angle may be more than 10 degrees.

The angle may be more than 20 degrees.

The angle may be more than 25 degrees.

The circuit board may be generally flat and lie in a plane.

The motor may have a longitudinal axis.

The battery may have a longitudinal axis.

The longitudinal axis of the motor may be parallel to the longitudinalaxis of the battery.

The plane may be disposed at an angle with respect to the longitudinalaxis of the battery and the longitudinal axis of the motor.

The angle may be greater than 5 degrees.

The angle may be greater than 10 degrees.

The angle may be greater than 15 degrees.

The angle may be greater than 20 degrees.

The angle may be greater than 25 degrees.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial side view of a cordless hand held vacuum cleaner ofthe related art with one housing side removed;

FIG. 2 is a partial side view of a cordless hand held screwdriver of therelated art with one housing side removed;

FIG. 3 is a close-up partial side view of a cordless hand heldscrewdriver of the related art with one housing side removed;

FIG. 4A illustrates a charger;

FIG. 4B schematically illustrates a charger and a hand-held vacuumcleaner or screwdriver which the charger may charge;

FIG. 5A schematically illustrates a charger and a hand-held vacuumcleaner or screwdriver which the charger may charge according to anexemplary embodiment of the present application;

FIG. 5B illustrates the exemplary embodiment of the charger shownschematically in FIG. 5A;

FIG. 6 is a partial side view of an exemplary embodiment of a cordlesshand held vacuum cleaner with one housing side removed;

FIG. 7 is another partial side view of an exemplary embodiment of acordless hand held vacuum cleaner with one housing side removed;

FIG. 8 is another partial side view of an exemplary embodiment of acordless hand held vacuum cleaner with one housing side removed;

FIG. 9 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 8 ;

FIG. 10 is another partial side view of an exemplary embodiment of acordless hand held vacuum cleaner with one housing side removed;

FIG. 11 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 10 ;

FIG. 12 is another partial side view of an exemplary embodiment of acordless hand held vacuum cleaner with one housing side removed;

FIG. 13 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 12 ;

FIG. 14 is another partial side view of an exemplary embodiment of acordless hand held vacuum cleaner with one housing side removed;

FIG. 15 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 14 ;

FIG. 16 is another partial side view of an exemplary embodiment of acordless hand held vacuum cleaner with one housing side removed;

FIG. 17 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 16 ;

FIG. 18 is another partial side view of an exemplary embodiment of acordless hand held vacuum cleaner with one housing side removed;

FIG. 19 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 18 ;

FIG. 20 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 18 ;

FIG. 21 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 18 ;

FIG. 22 is close-up view of a portion of the cordless hand held vacuumcleaner of FIG. 18 ;

FIG. 23 is a side view of a hand held cordless vacuum cleaner which mayinclude the internal configuration of the exemplary embodiments shown inFIGS. 6 to 22 ;

FIG. 24 is a side view of a cordless screwdriver according to anexemplary embodiment with one housing side removed;

FIG. 25 is a perspective view of the cordless screwdriver of FIG. 24 ;

FIG. 26 is a close-up side view of the cordless screwdriver of FIG. 24 ;

FIG. 27 is an illustration of another embodiment of a switch;

FIG. 28 is a perspective view of another exemplary embodiment of acordless screwdriver shown with the housing side;

FIG. 29 is a sideview of the exemplary embodiment of the screwdriver ofFIG. 28 shown with one housing side removed;

FIG. 30 is a side view of the internals of screwdrivers of exemplaryembodiments of the present application;

FIG. 31 is a perspective side view of internals of a screwdriveraccording to another exemplary embodiment;

FIG. 32 is a perspective view of a portion of another exemplaryembodiment of a hand-held vacuum cleaner with a housing shell sectionremoved;

FIG. 33 is a perspective view of a battery cell;

FIG. 34 is a perspective view of the battery cell with a negative cellstrap;

FIG. 35 is a perspective view of the battery cell with a pair of cellstraps;

FIG. 36 is a perspective view of a battery assembly including thebattery cell;

FIG. 37 is a perspective view of a motor;

FIG. 38 is a perspective view of the motor with a fan attached;

FIG. 39 is a perspective view of the motor with the fan and a positiveconnector attached;

FIG. 40 is a perspective view of the motor with the fan and a pair ofconnectors attached;

FIG. 41 is a perspective view of a housing shell of the hand-held vacuumcleaner of the exemplary embodiment;

FIG. 42 is a perspective view of the housing shell with a batteryassembly;

FIG. 43 is a perspective view of the housing shell with a pair ofbattery assemblies;

FIG. 44 is a perspective view of the housing shell with the pair ofbattery assemblies and a motor assembly;

FIG. 45 is another perspective view of the exemplary embodiment of thehand-held vacuum cleaner with a housing shell section removed;

FIG. 46 is a side view of the exemplary embodiment of the hand-heldvacuum cleaner with a housing shell section removed;

FIG. 47 is another side view of the exemplary embodiment of thehand-held vacuum cleaner with a housing shell section removed;

FIG. 48 is another side view of the exemplary embodiment of thehand-held vacuum cleaner with a housing shell section removed;

FIG. 49 is a side view of a portion of the exemplary embodiment of thehand-held vacuum cleaner;

FIG. 50 is a top view of a portion of the exemplary embodiment of thehand-held vacuum cleaner with a housing shell section removed;

FIG. 51 is a rotated top view normal to the printed circuit board, of aportion of the exemplary embodiment of the hand-held vacuum cleaner witha housing shell section removed;

FIG. 52 is a side view of an exemplary embodiment of a screwdriver withhousing parts removed;

FIG. 53 is a top view of a circuit board;

FIG. 54 is a side view of another exemplary embodiment of a screwdriverwith housing parts removed;

FIG. 55 is a top view of a circuit board;

FIG. 56 is a perspective view of a connector;

FIG. 57 is a side view of another exemplary embodiment of a screwdriverwith housing parts removed;

FIG. 58 is a top view of a circuit board;

FIG. 59 is a perspective view of a connector;

FIG. 60 is a side view of another exemplary embodiment of a screwdriverwith housing parts removed;

FIG. 61 is a top view of a circuit board;

FIG. 62 is a perspective view of a connector;

FIG. 63 is a rear perspective view of a related art socket structure;

FIG. 64 is a rear view of the related art socket structure;

FIG. 65 is a rear perspective of an exemplary embodiment of a socketstructure;

FIG. 66 is a rear perspective view of the exemplary embodiment of thesocket structure with a printed circuit board connected thereto;

FIG. 67 is a side view of the exemplary embodiment of the socketstructure with a printed circuit board connected thereto;

FIG. 68 is a rear view of the exemplary embodiment of the socketstructure with a printed circuit board connected thereto;

FIG. 69 is a perspective view of a related art socket structure;

FIG. 70 is a perspective view of a related art socket structure;

FIG. 71 is a front perspective of the exemplary embodiment of the socketstructure; and

FIG. 72 is a perspective view of an exemplary embodiment of a chargerplug.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

It may be desirable to provide simplified manufacture of powered toolsor home products. Simplified manufacturing may result in improvements incosts, manufacturing and reliability.

FIG. 1 illustrates a partial view of a related art hand held vacuumcleaner (“hand vac”) 100 with one housing side removed. The hand vac 100has a housing 101 with a handle section 102. The hand vac 100 furtherincludes a motor 150 which drives a fan 160. The fan 160 creates suctionfor drawing dirt, dust and debris into a canister (not shown), as iswell known in the art. The motor 150 is powered by a battery 130 and thebattery 130 is mounted on a PCB 140. The battery 130 may be alithium-ion battery. The hand vac 100 also includes a switch 110 foractivating the motor 150 and a socket 120 through which the battery 130can be charged. As is shown and will be appreciated, there are a numberof wires 170 which connect the various components. For example, wires170 are used to connect the switch 110, motor 150 and battery 130 sothat when a user actuates the switch 110, the battery 130 provides powerto the motor 150. Wires 170 are also used to connect the socket 120 tothe battery 130 so that the battery 130 can be charged.

The wires 170 of FIG. 1 may contact one another. Accordingly, therelated art of FIG. 1 includes wires 170 which are insulated with athermoplastic so that they can contact one another without causing ashort circuit or other malfunction. Thermoplastic wires 170 aregenerally installed by hand, are stripped to expose their ends and alsosoldered at the appropriate points. Thus, manufacture of the related arthand vac 100 of FIG. 1 may require various steps related to the wires.

The basic operation and construction of a hand-held vacuum cleaner isknown, and is shown in, for example, U.S. Pat. Nos. 4,209,875 and8,549,704 and US Patent Application Publication No. 2009/0260179; eachof which are herein incorporated by reference in their entirety.

A power tool 200 in the form of a related art screwdriver is shown inFIGS. 2 and 3 . FIG. 2 illustrates the screwdriver 200 with one housingside removed and FIG. 3 illustrates the same in the close-up area of aswitch. The screwdriver 200 includes a motor 250 which drives an outputspindle 260. The output spindle 260 holds a screwdriver bit forperforming a screwdriving operation. A transmission 261 may be disposedbetween the motor 250 and the output spindle 260.

As shown, the screwdriver 200 includes a housing 201 with a handlesection 202. A battery 230 is disposed in the handle section 202 and isadjacent a printed circuit board (“PCB”) 240. The battery 230 may be alithium-ion battery. The screwdriver 200 has a socket for providing acharge to the battery 230 and there is a switch 210 so that a user canoperate the screwdriver 200. Wires 270 connect the various parts such asproviding a connection from the battery 230 to the motor 250 so that themotor 250 can be powered. Similarly, wires 270 are provided from thesocket 220 to the circuit board 240. In this case, contacts 211 on theswitch 210 engage contacts 212 on the circuit board 240 to complete acircuit and engage the motor 250.

Wires 270 are insulated with a thermoplastic, and are of the same typeas wires 170 described above with respect to hand vac 100.

The basic operation of a screwdriver is well known and one example isshown in U.S. Pat. No. 7,134,364, which is hereby incorporated byreference in its entirety.

FIG. 4A illustrates a charger 299 with a charging block 300. As will beappreciated, the charger 299 can be plugged into an electrical outlet atone end 298 and plugs into socket 120 or 220 at the other end 297 tocharge the respective tools 100/200.

FIG. 4B schematically illustrates the charger 299 and the in toolcircuit boards 140/240. As shown, the charger 299 provides a chargethrough socket 120/220. The charger 299 provides a constant currentsupply of, for example, 150 mA. It does not include any overchargeprotection. The circuit boards 140/240 each include a primary cellmonitor 301 and a secondary cell monitor 302. The primary cell monitor301 monitors the voltage and prevents an overvoltage in the batteries130 or 230. The secondary cell monitor 302 also monitors the voltage andprevents overvoltage in the batteries 130, 230 in the event of amalfunction of the primary cell monitor 301. An independent chargershut-off 303 for shutting off charge to prevent an overvoltage whenindicated by the primary or secondary cell monitors 301/302 is providedon the in-tool circuit board 140/240.

Exemplary embodiments of the present application include variousstructures for a simplified design. FIG. 5A illustrates a schematic of acharger and a tool and FIG. 5B shows a charger 310. The charger 310 isvisually similar to the charger 299 and has the same outside structuralfeatures. In particular, the charger 310 has a charging block 311 withprongs for fitting into a wall outlet. It also has a far end 313 whichfits into a socket 120/220 of a tool 1000 (hand vac or screwdriver).Accordingly, it plugs into a wall outlet one end and a socket of a powertool or home product on the other end and provides a constant currentsupply of 150 mA. However, unlike the charger 299, the charger 310 alsoincludes a primary cell monitor 401, secondary cell monitor 402 and anindependent charge shutoff 403. In the embodiment of FIG. 4B, thesefeatures are in the tool. The primary cell monitor 401, secondary cellmonitor 402 and independent charge shutoff 403 work in the same manneras the elements 301, 302 and 303. That is, the primary cell monitor 401monitors the voltage of one or more batteries 430 so that an overvoltagecan be prevented. The secondary cell monitor 402 similarly monitors thevoltage of the one or more batteries 430 so that an overvoltage can beprevented. The battery 430 may be a lithium-ion battery. The independentcharge shutoff 403 can shut off a charge in the event an overvoltage isdetected. In FIG. 5A, the primary cell monitor 401, secondary cellmonitor 402 and the independent charge shutoff 403 are now located inthe charger, particularly on a circuit board contained in the chargingblock 311 portion of the charger 310. Accordingly, these features arenot necessary in the tool.

Hand vac or power tool 1000 is shown schematically in FIG. 5A and theschematics there are applicable to the various hand vacs and power toolsdescribed later in the application. As shown in FIG. 5A, the hand vac orpower tool 1000 no longer requires cell monitors or an independentcharge shutoff. Accordingly, it may simply have a socket 420 and a motor450. Since the vac or tool 1000 does not include cell monitoring, acircuit board is no longer necessary. However, as discussed below, someembodiments may include a circuit board. This configuration allows avariety of different constructions for hand vacs and power tools. Theschematic for the hand vac or power tool 1000 is applicable to thespecific hand vacs and power tools shown and discussed below.

FIG. 6 illustrates a partial view of an exemplary embodiment of ahand-held vacuum cleaner (“hand vac”) 500 with one housing side removedwhich can be used in conjunction with the charger 310 and tool 1000configuration shown in FIG. 5A. That is, the hand vac 500 may have thegeneral operation of the schematically described hand vac 1000 in FIG. 5. Additionally, the hand vac 500 may be used with the charging block 310described above with reference to FIGS. 5A and 5B.

The hand vac 500 has a housing 501 with a handle section 502. The handvac 500 further includes a motor 450 which drives a fan (not shown). Thefan (not shown) creates suction for drawing dirt, dust and debris into acanister (not shown), as is well known in the art. The motor 450 ispowered by a battery 430. The battery 430 may be a lithium-ion batteryor another battery type which requires voltage monitoring and control.The hand vac 500 also includes a switch 403 for activating the motor 450and a socket 420 through which the battery 430 can be charged. The samereference numerals will be used below for the same components.

As shown in FIG. 6 , since the primary cell monitor 401, secondary cellmonitor 402 and independent charge shut-off 403 are included in thecharging block 310, it is not required to include them in the hand vac500. In the exemplary embodiment of the hand vac 500 in FIG. 6 , nocircuit board at all is necessary. As shown in FIG. 6 , wires 170 areused to connect the battery 430, switch 403, socket 420 and motor 450.In this case, the battery 430 can be disposed in the handle section 502.As can be seen, the wiring of this exemplary embodiment is simplified.This can both reduce the cost of manufacturing the hand vac 500.

FIG. 7 illustrates another exemplary embodiment of a hand vac 600. Handvac 600 is essentially the same as hand vac 500, except that it usesdifferent wires. Hand vac 500 uses traditionally insulated wires 170.Hand vac 600 utilizes wires 670 which may be enameled or uninsulated.Enameled wire (also known as magnet wire) is a solid copper conductorwhich is covered with a thin layer of insulation. The insulation may bemade of a tough polymer film. Enameled wire lends itself to automaticfeeding. Accordingly, the wiring of FIG. 7 more easily lends itself tomachine wiring. The simplified construction of the vac 600 allows forwires 670 to be used instead of the thermoplastic insulated wires 170 asthe wiring is simpler and less prone to inadvertent contact. The wires670 may be used to connect the socket 420 and the battery 430, theswitch 403 and the motor 450 in a way that allows the power to betransferred through the socket 420 to the battery 430 in order to chargethe battery 430. The wires 670 also allow the battery 430 to power themotor 450, per control of the switch 403.

As noted, the wires 670 may even be uninsulated wires in someembodiments. Uninsulated wires can simply be a solid copper wire. Use ofan uninsulated wire is particularly simple as no insulating layer needsto be removed to make electrical connections.

FIGS. 8 and 9 illustrate another exemplary embodiment of a hand vac 601.The hand vac 601 illustrates another simplified construction. In thisinstance, the connection between the motor 450 and the battery 430 isprovided by a circuit board 650. As shown, the motor 450 and the battery430 are each soldered onto the circuit board 650 and no wires arenecessary for the connection. In the hand vac 601, the entire assemblyof the battery 430, motor 450 and circuit board 650 can be placed intothe housing 501 in one operation. That is, the battery 430 and the motor450 can each be soldered to the circuit board 650. Then, the resultingassembly can all be inserted into the housing 501 together. This canreduce the number of steps needed for assembly. Additionally, it lendsitself to machine assembly.

As shown in FIG. 9 , the battery cell 430 may have a battery cap 425with a positive electrode 426 and a negative electrode 427 so that thepositive and negative terminals from the battery cell 430 are providedat a similar location. The battery cell 430 includes a positive end anda negative end. A cell strap 428 may be provided from one end of thebattery cell 430 to the battery cap 425 and the battery cap 425 may belocated at the other end. That provides the battery cap 425 with accessto both the positive and negative terminals of the battery and allows itto provide the positive and negative electrodes 426, 427. The positiveand negative electrodes 426, 427 may be stamped metal connectors and, assuch, may have rigidity. Additionally, they may mate with locations 661and 662 on the circuit board 650. The locations 661 may be designed toreceive electrodes. They may include slots.

The motor 450 includes a positive terminal 452 and a negative terminal453. The positive terminal 452 is connected to the circuit board atlocation 663 and the negative terminal 453 is connected to the circuitboard at location 664. The positive and negative terminals 452 and 453may be stamped metal and have rigidity. The locations 663, 664 may bedesigned to receive terminals and may include slots.

As will be appreciated, power is provided from the battery 430 to themotor 450 through the circuit board 650. The circuit board 650 mayinclude conductive traces to provide the connection.

The order of operations for assembly may be different in differentembodiments. For example, the battery 430, motor 450 and circuit board650 can all be inserted into the housing 501 and then they can besoldered together. It is also possible that some sub-assemblies can beinserted and soldered together at different times. For example, thebattery 430 can be soldered to the circuit board 650 and it can beinserted into the housing 501. Then, the motor 450 can be inserted intothe housing 501 and soldered to the circuit board 650.

Various components, such as the socket 420 are not shown in FIG. 8 . Thehand vac 601 operates similarly to previously and subsequently describedvacs.

FIGS. 10 and 11 illustrate another exemplary embodiment of a hand vac602. The hand vac 602 is similar to the hand vac 601, but includes twobatteries 430 and a circuit board 651 designed to connect to bothbatteries 430. In this exemplary embodiment, the two batteries 430, themotor 450 and the socket 420 all are soldered directly onto a circuitboard 651. This provides another easy to manufacture hand vac design. Aswith the embodiment of FIGS. 8 and 9 , the two batteries 430 and themotor 450 can all be soldered to the circuit board 651 and the entireassembly can be inserted into the housing 501 together. Also, the ordercan be changed, as described above. Power from both of the batteries 430can be provided to the motor 450 through the circuit board 651. Asdiscussed previously, this may be done by having conductive traces onthe circuit board 651.

FIGS. 12 and 13 illustrate another exemplary embodiment of a hand vac603. The exemplary embodiment of a hand vac 603 shown in FIGS. 12 and 13is similar to hand vac 602. However, the motor 450 and batteries 430 areconnected to circuit board 652 by tulip connectors 653. Thus, the motor450 and batteries 430 may be connected by sliding contacts into thetulip connectors 653 rather than soldering. For example, the circuitboard 652 may be positioned in the housing 501. Ribs or other placementfeatures in the housing 501 may hold the circuit board 652 in theappropriate location. Then, the batteries 430 may be slid into place inthe housing 501 and the motor 450 may be slid into place in the housing501. Ribs or other placement features of the housing 501 may serve as atype of placement device or jig to assist with assembly. Although notshown, the circuit board 652 could also connect to a socket 420 viatulip connectors 653.

In other embodiments, tulip connectors 653 and soldering could both beused. For example, the motor may be connected to a circuit board bytulip connectors and a battery may be connected by soldering.

FIGS. 14 and 15 illustrate another exemplary embodiment of a hand vac604. This embodiment includes two wires as well as several stamped metalconnectors. In particular, one wire 170 is connected between socket 420and a first, positive end of the battery 430. A second wire 170 isconnected between the socket 420 and an end of the motor 450. As noted,there are also three stamped metal connectors 171, 172 and 173. Thestamped connector 173 connects a negative end of the battery 430 to anegative terminal of the motor 450. Stamped connector 171 selectivelyconnects a positive terminal of the motor to a positive end of thebattery 430. Stamped connector 172 is affixed to a positive terminal ofthe battery and cooperates with stamped connector 171 to turn on and offthe hand vac 604.

In usage, when the charging block 310 is plugged into the hand vac 604at the socket 420, a charging current is provided to the battery 430 tocharge the battery. The socket 420 is connected to the negative end ofthe battery 430 through a first wire 170 and stamped connector 173. Thesocket 420 is connected to the positive end of the battery through asecond wire 170 and stamped connector 172. The second wire 170 may beconnected to the stamped connector 172 and provide an electrical paththrough the connector 172 or the second wire 170 may be directlyattached to the positive end of the battery 430. The motor 450 isconnected to a negative end of the battery 430 by connector 173.

The motor 450, and thus the hand vac 604, is off when the connectors 171and 172 are spaced, as is shown in FIG. 15 . In order to activate themotor 450 (and thus the hand vac 406), a user may use a switch (notshown) which will move the connector 171 so that it contacts connector172 and completes the circuit. Specifically, when the connector 171 and172 are in contact, the positive end of the battery 430 is connected toa positive terminal of the motor 450. This turns on the motor 450 so asto operate the hand vac 604.

FIGS. 16 and 17 illustrate another exemplary embodiment of a hand vac605. This embodiment includes a single wire 170 and several stampedmetal electrical connectors 271, 272 and 273. As shown, the wire 170provides a connection between the socket 420 and a negative terminal ofthe motor 450. A stamped metal electrical connector 271 is providedbetween the socket 420 and a positive end 431 of the battery 430. Thestamped connector 271 also serves as one part of the activation switch.A second stamped connector 272 is connected to a positive terminal ofthe motor 450 and serves as the other part of the activation switchmechanism. A third stamped connector 273 connects a negative end of thebattery 430 to the motor. As shown in FIGS. 16 and 17 , the connector273 connects to a far end of the motor can. The motor can itself is thenused to electrically connect to the negative terminal. Thus, theconnector 273 can connect to the motor 450 near the motor output shaft451, but provide the appropriate connection to the negative terminal.

In usage, when the charging block 310 is plugged into the hand vac 605at the socket 420, a charging current is provided to the battery 430 tocharge the battery. The socket 420 is connected to a negative terminalof the motor 450 through a wire 170. The negative terminal of the motor450 is connected to the connector 273 through the motor can, asdescribed above. The connector 273 connects the motor can to thenegative end 432 of the battery 430. The socket 420 is connected to thepositive end 431 of the battery 430 directly through connector 271.Accordingly, a charge can be provided to the battery 430 through thesocket to charge the battery 430.

The hand vac 605 is turned on in a similar manner as the hand vac 604,described above. Particularly, it is turned on by creating a connectionbetween two connectors 271 and 272. When not turned on, the connectors271 and 272 are separated (as show in FIGS. 16 and 17 ) and the circuitto the motor is not completed. In order to turn on the motor 450, andthus the hand vac 605, the connectors 271 and 272 are brought intocontact to complete the circuit (done by user switch; not shown). Inparticular, the positive terminal 431 of the battery 430 is connected tothe positive terminal of the motor through connectors 271 and 272. Thenegative terminal 432 of the battery 430 connects to the negativeterminal of the motor 450 through the connector 273 and the motor can.

The user switch (not shown) may be a simple mechanical switch whichdepresses the connector 272 towards the connector 271. The switch may bea momentary switch, which the user needs to maintain in a depressedstate to keep the power on or it may be a non-momentary switch.

FIGS. 18-22 illustrate another exemplary embodiment of a hand vac 606.As with the previous embodiments, a charging current can be provided tothe battery 430 through the socket 420. The socket 420 is connected to apositive terminal 431 of the battery 430 through a stamped metalelectrical connector 274. The socket 420 is connected to a negativeterminal 432 of the battery 430 through a wire 170, the motor can andstamped metal electrical connector 276. Particularly, the socket 420 isconnected to a negative terminal of the motor 450 through wire 170. Thenegative terminal 423 of the battery 430 connects to the motor can andin this way provides the connections necessary for charging the battery430.

Similar to the previous embodiments, the motor 450 is activated byproviding a connection between stamped metal electrical connectors 274and 275. As shown, connector 275 is connected to a terminal of the motor450. When the connector 275 is depressed so that it contacts connector274, a circuit is completed in order to run the motor 450. As with theprevious embodiments, this connection can be made by a user switch (notshown).

FIG. 23 illustrates a fully assembled hand vac. This arrangement isapplicable to any of the embodiments shown in FIGS. 6-22 or laterembodiments of hand vacs. As shown, the hand vac has a dust canister 901into which dust, dirt and debris is drawn. This occurs because of thesuction force provided by the motor driven fan. In particular air ispushed out of exhaust 902 and sucked in at opening 903. A user can holdthe hand vac by the handle so that it is a hand-held vacuum. The handvac 900 may also have a filter 904 in the dust canister 901 forfiltering the dust from the air.

The configuration of the charging block 310 and product 1000 shown inFIG. 5 and those shown for specific vac configurations in FIGS. 6-22 mayalso be applied to power tools such as screwdrivers and drills andparticularly to handheld power tools. Several specific exemplaryembodiments for screwdrivers are shown below, but other applications ofthe principles of the hand vac configurations may also be applied.

FIGS. 24-26 illustrate an exemplary embodiment of a screwdriver 700 witha simplified construction. As shown in FIGS. 2 and 3 , and discussedabove, related art screwdrivers include a circuit board 240 whichcooperates in the switching on and off of the screwdriver and on whichcharging circuitry is included. In the exemplary embodiment of FIGS.24-26 , the primary cell monitor 401, secondary cell monitor 402 andindependent charge shut-off 403 are located in the charging block 310.Accordingly, the screwdriver 700 does not need to include the monitoringor shut off circuitry 401, 402, 403. As a result, the screwdriver 700also does not require a circuit board for such circuitry.

FIG. 24 is a side view of the screwdriver 700 with one side of a housing701 removed. FIG. 25 is a perspective view of the screwdriver 700 withone side of the housing 701 removed. FIG. 26 is a close-up side view ofthe screwdriver with one side of the housing 701 removed.

The exemplary embodiment of the screwdriver 700 includes a motor 450which drives an output spindle 760. The output spindle 760 holds ascrewdriver bit for performing a screwdriving operation. A transmission751 is disposed between the motor 450 and the output spindle 760.

As shown, the screwdriver 700 includes a housing 701 with a handlesection 702. A battery 430 is disposed in the handle section 702. Asdiscussed above, the battery 430 may be a lithium-ion battery. Thescrewdriver 700 has a socket 420 for providing a charge to the battery430 and there is a switch 710 so that a user can operate the screwdriver700. The switch has a pivot 711 around which the switch 710 pivots. Theend of the switch 710 opposite the pivot 711 is biased outwardly by aspring 712.

The screwdriver 700 includes a number of stamped metal electricalconnectors 713/714/720, 715, 716, 717 and 718. It also includes a pairof wires 170. It will be appreciated As with the vac embodiments above,the battery 430 can be charged through the socket 420 when the chargingblock is connected with the socket 420 to provide a charging current.The socket 420 is connected to a positive terminal 431 of the battery430 by connector 718 and is connected to the negative terminal 432through connector 716. Accordingly, the battery 430 can be chargedthrough the socket 420.

In order to turn on the motor 450 so as to use the screwdriver 700, auser depresses the switch 710. As noted above, the switch pivots about711 against the force of spring 712. The connector 720 is disposed onthe switch 710 and has ends 713 and 714. When a user depresses theswitch 710, ends 713 and 714 of connector 720 contact ends of connectors715 and 717 to complete a circuit and provide power from the battery 430to the motor 450. When the user releases the switch 710, the ends 713and 714 of connector 720 move away from connectors 715 and 717 and thecircuit is not completed, so that the motor 450 is not provided withpower from the battery 430 and the motor 450 does not operate.

Connector 716 is connected to a negative terminal of the battery and awire 170 connects the connector 716 to a negative terminal of the motor450. Another wire 170 is connected to a positive terminal of the motor450. When the switch 710 is depressed, power from the positive terminal431 travels through the connector 717, through connector 720 and throughconnector 715. Connector 715 is connected to the wire 170 which isconnected to the positive terminal of the motor 450. In this manner,power from the battery 430 flows to the motor 450 and the screwdriver700 is turned on. In FIGS. 24-26 , the switch 710 is shown in a positionwhere the motor is not activated.

Connection of the connector 720 with the connectors 715 and 717 make theswitch that is shown schematically in FIG. 5 as switch 403.

FIG. 27 shows another method of implementing the switch 403 in thescrewdriver 700. In the embodiment of FIG. 27 , the connector 720 iseliminated. The connector 715 is extended and made with a hinge so thatthe connectors 715 and 717 can contact one another directly. In thiscase, the connectors 715 and 717 are separated in the off position. Auser can then depress switch 710 to push connector 715 towards connector717 so that the two connectors make contact and an electrical currentruns between them. The screwdriver 700 otherwise operates the same as isshown in FIGS. 24-26 .

Another exemplary embodiment of a screwdriver is shown in FIGS. 28 and29 . The screwdriver 800 is similar to the screwdriver 700. However, itincludes different electrical connections and a circuit board 820 toprovide connections between the battery 430 and the motor 450. As shownin FIGS. 28 and 29 , battery 430 is soldered onto a circuit board 820.Circuit board 820 is also connected to motor 450. In order to turn onthe motor, the switch 710 is depressed to connect connector 717 and 715and close the circuit to provide power to the motor.

As shown in FIG. 29 , the screwdriver 800 may include a second circuitboard 821 which connects the battery to a light 855. Accordingly, whenthe switch 710 is depressed, a connection is also made to provideelectric power to the light 855.

As shown in FIG. 30 , there may separate circuit boards 850 and 851 forthe motor and the light or a single combined circuit board 852.Additionally, as shown in FIG. 30 , the switch may 710 may be moved toprovide a connection directly onto the circuit board 850.

FIG. 31 illustrates another exemplary embodiment of internals of ascrewdriver 805. As shown, a circuit board 825 connects the battery tothe motor. In particular, a charger 310 connects to the socket 420 toprovide a charging current. Stamped metal connector 723 connects thesocket 420 to a positive terminal 431 of the battery 430. The socket 420is connected to the circuit board 825 through another stamped metalconnector 724. The circuit board then connects to a negative terminal432 of the battery 430 through the circuit board. Accordingly, thebattery 430 can be provided with a charge. In order to operate thescrewdriver, the user actuatable switch 710 is depressed to bring theconnector 720 into contact with connectors 723 and 724. The connector724 connects a negative terminal of the battery 430 to the circuit board825. When the connection is completed by contacting the connector 720with the connectors 723 and 724, the positive terminal 431 is alsoconnected to the circuit board 825 so that a circuit can be completedand power provided to the motor 450 to operate the screwdriver. As willbe appreciated, various electrical connections can be made in thecircuit board 825 by printings on the board, such as conductive traces.This is the case will all of the circuit boards disclosed in the variousembodiments. It will additionally be appreciated that similarconstructions may be applied to, for example, a drill.

Another exemplary embodiment of a hand vac will be described withrespect to FIGS. 32-51 . Like parts are described with the samereference numbers as previously. The hand vac 607 is shown with part ofthe housing 610 removed in FIG. 32 and without the canister sectionshown in FIG. 23 . It will be appreciated that, as with the other handvac embodiments, the hand vac 607 operates in the same manner describedwith respect to FIG. 23 .

As shown in FIG. 32 , the hand vac 607 of this exemplary embodimentincludes a pair of batteries 430 and a motor 450 located between thebatteries 430. The batteries 430 are attached to a circuit board 860. Aswitch 865 is also attached to the circuit board 860 and is used to turnon the hand vac 607. Assembly of the hand vac 607 and further details ofits structure are shown in FIGS. 33-51 .

FIG. 33 illustrates one of the batteries 430. As previously discussed,the battery 430 may be a cylindrical battery cell, such as an 18650 sizecylindrical battery cell, with a lithium-ion chemistry. Other shapes,sizes and battery chemistries are also possible.

As shown in FIG. 34 , a negative cell strap 434 is welded to thenegative terminal 432 of the battery 430. The negative cell strap 434 isconductive and may be a stamped metal connector. As shown in FIG. 34 ,the negative cell strap 434 travels from the negative battery terminal432 along a side of the battery 430 and extends to a position adjacentthe positive terminal 431.

The negative cell strap 434 may have a width w which is significantlygreater than the thickness. For example, the negative cell strap 434 mayhave a width w of 4 mm and a thickness t of 1 mm. The width w may betwice as much as the thickness t or more; three times as much as thethickness t or more; or four times as much as the thickness t or more.The relative large size of a width versus the thickness may be true forall of the stamped metal connectors discussed previously orsubsequently. For example, each may have a width that is two or moretimes, three or more times; or four or more times as great as itsthickness.

As shown in FIG. 35 , a positive cell strap 440 may be subsequentlywelded onto the positive terminal 431 of the battery 430. As will beappreciated, the positive cell strap 440 is also conductive and may be astamped metal connector. The positive cell strap 440 includes an end 441which is parallel and adjacent to an end 435 of the negative weld strap434.

As shown in FIG. 36 , foam pads 460 and 461 may then be applied to thebattery cell 430. The foam pad 460 is a cylindrical foam pad and coversthe negative terminal 430 of the battery 430 and a portion of thenegative cell strap 434. The foam pad 461 is a partial cylinder, suchthat the ends 435 and 441 are allowed to project freely. In otherembodiments, the foam pads may be different shapes or sizes. The foampads 460, 461 may be attached by an adhesive or other means.

FIGS. 33-36 illustrate a progression of assembly steps related to thebattery cell 430 and accompanying components. In the illustratedexemplary embodiment, the assembly steps are carried out in the ordershown from FIGS. 33-36 . Specifically, first the battery 430 isprovided, as shown in FIG. 33 . Then, the negative cell strap 434 iswelded to a negative terminal 432 of the battery, as shown in FIG. 34 .After that, the positive cell strap 440 is welded onto the battery 430,as shown in FIG. 35 and, finally, the foam pads 460, 461 are added, asshown in FIG. 36 . Although that specific order is illustrated for thisexemplary embodiment, this specification contemplates other orders ofassembly. For example, the positive cell strap 450 may be welded to thebattery 430 before the negative cell strap 434 is welded to the battery430.

Additionally, the hand vac 607 includes two batteries 430. The batteryassembly described with reference to FIGS. 33-36 is repeated for bothbatteries 430. In embodiments with only one battery 430, only onebattery assembly per hand vac is necessary. When there are multiplebatteries 430, the order of assembly for the different batteries may bedifferent. For example, for a first battery 430, the positive cell strap450 may be welded to the battery 430 before the negative cell strap 434is welded to the battery 430 and for a second battery 430 the positivecell strap 450 may be welded to the battery 430 after the negative cellstrap 434 is welded to the battery 430.

A motor assembly operation will now be described with reference to FIGS.37-40 . FIG. 37 illustrates a motor 450. The motor 450 has an outputshaft 451, a positive terminal 452 and a negative terminal 453. As shownin FIG. 38 , after the motor 450 is provided, a fan 160 is pressed ontothe output shaft 451 of the motor 450. Then, as shown in FIG. 39 , apositive connector 454 is attached to the positive motor terminal 452.Next, as shown in FIG. 40 , a negative connector 455 is attached to thenegative motor terminal 453. The positive connector 454 has an end 456which is parallel to an end 458 of the negative connector 455. Theconnectors 454 and 455 are conductive and may be made of metal.

This disclosure contemplates other orders of assembly as well. Forexample, the fan 160 may be attached to the motor output shaft 451before, after or between the attachment of the positive connector 454and the negative connector 455 to the motor 450. Additionally, in theshown exemplary embodiment, the positive connector 454 is attachedbefore the negative connector 455. In other embodiments, the negativeconnector 455 may be attached before the positive connector 454.

FIGS. 41-51 illustrate assembly of the battery assembly and the motorassembly into the housing 610. As shown in FIG. 49 , the housing 610comprises a first housing shell 611 and a second housing shell 612. Thefirst and second housing shells 611, 612 form the housing 610, includinga handle portion 613, which the user can grip.

FIG. 41 illustrates the first housing shell 611. The first housing shell611 includes features for holding the batteries 430, motor 450 circuitboard 860 and other components. That is, the components can be placedinto the shell and the shell 611 holds them in the appropriate location.As shown in FIG. 41 , there are a variety of ribs for holding thecomponents. The later Figs. illustrate the ribs holding the components.

As shown in FIG. 42 , the battery assembly 470 shown in FIG. 36 isplaced into the first shell 611. Next, as shown in FIG. 43 , a secondbattery assembly 470 is placed into the shell 611. In this instance twoof the same battery assemblies 470 are placed into the shell 611. Inother embodiments with multiple battery assemblies, the batteryassemblies may be different from one another. Additionally, the order inwhich the two battery assemblies 470 are placed in the shell 611 may beswitched.

As shown in FIG. 44 , the motor assembly 480 is then placed in the shell611. As shown in FIGS. 45 and 46 , the circuit board 860 and switch 865are inserted into the shell 611. The switch 865 is attached to thecircuit board 860 before the circuit board 860 is inserted into theshell 611. Next, as shown in FIG. 47 , the housing shell 611 is rotatedto aid in the soldering operation. Soldering is then performed. Thesoldering operations solders the battery assemblies 470 and the motorassembly 480 to the circuit board. Specifically, ends 441, 435, 456 and458 of the connectors are all soldered to the circuit board 860. For thebattery assemblies 470, both sets of ends 435, 441 are soldered. Thiselectrically connects the batteries 430 and the motor 450 to the circuitboard 860, and allows for connection from the batteries 430 to the motor450 to power the motor 450 through the circuit board. Since the switch865 is also connected to the circuit board 860, it can be used to turnon or off the hand vac 607 by the batteries 430 providing power to themotor 450 or not.

As shown, the circuit board 860 includes a number of places forreceiving the ends 441, 435, 456 and 458. The circuit board 860 may haveslots or other receiving portions such that an electrical connection canbe formed when the ends contact the circuit board 860 at the receivingportion.

FIGS. 46, 47 and 48 illustrate the rotation of the housing shell 611. Inthe position shown in FIGS. 46 and 48 , the motor 450 and the batteries430 are horizontal. The circuit board 860 is angled with respect to themotor 450 and the batteries 430 at an angle of 30 degrees. Particularly,the motor 450 has a motor longitudinal axis A. The batteries 430 includea longitudinal axis B and the circuit board 860 is along a plane C. Theangle Θ′ between the longitudinal axis A and the plane C is 30 degrees.Likewise, the angle Θ between the longitudinal axis B and the plane C is30 degrees. The motor 450 and the batteries 430 are parallel, such thatthe angle between them and the circuit board 860 is the same in thisembodiment.

When the housing shell 611 is rotated to the position in FIG. 47 , thecircuit board 860 is disposed horizontally. This allows a verticallytravelling and disposed soldering machine to more easily solder theconnectors to the circuit board 860.

As shown in FIG. 48 , after the soldering is completed, the shell 611 isrotated back from the position of FIG. 47 to its previous position.Next, as shown in FIG. 49 , the second housing shell 612 is attached tothe first housing shell 611. The first housing shell 611 and the secondhousing shell 612 may be attached by any of various means, such asscrews, rivets or other attaching means. When the second housing shell612 is attached to the first housing shell 611, the components whichwere placed in the first housing shell 611 are held therebetween.

FIG. 50 is a top view of the housing shell 611 in the position of FIGS.46 and 48 . FIG. 51 is a top view of the housing shell 611 in theposition of FIG. 47 . A canister 901, as shown in FIG. 23 , can then beadded to complete the hand-held vacuum cleaner. The canister 901 isadded adjacent the fan 160 and suction of air and debris is performed inthe manner described above.

As is understood, the various conductive metal connectors describedabove are fixed. They are also rigid such that they do not move asignificant amount under the normal forces of gravity, but stay inplace. This is in contrast to, for example, the wires 170 discussedabove which lack such rigidity. Accordingly, for example, when thebattery assemblies 470 are assembled into the first housing shell 611,the connectors of the battery assembly 470 are sufficiently rigid thatthey can contact the circuit board at a particular location and can besoldered in place. In other embodiments, tulip or other connectors maybe used instead of soldering.

As with the other embodiments, the general structure and methoddescribed above with respect to the hand vac 607 shown in FIGS. 32-51may be applied to other home products or tools. For example, a similarstructure and method may be employed to construct a drill or ascrewdriver. In the event of constructing a drill or screwdriver, thefan may be omitted or a fan operable to cool operation of the tool maybe used. Additionally, a transmission may be pressed onto the outputshaft of the motor. As will be appreciated, in the case of a drill achuck and other traditional drill components are added to the drill,such as the drill components shown in U.S. Pat. No. 7,497,275, which isincorporated herein, by reference. In the case of a screwdriver, a hexbit holder is added. In either event, a chuck may also be present.Similarly, a hand-held trimmer or other outdoor power tool may beconstructed according to the above structure and method. The hand-heldtrimmer would include traditional trimmer components, such as thoseshown in U.S. Pat. No. 3,757,194 and U.S. Design Pat. No. 548,028. U.S.Pat. No. 3,757,194 and U.S. Design Pat. No. 548,028 are bothincorporated herein, by reference, in their entireties.

Various embodiments of screwdrivers and their components are shown inFIGS. 52-62 . FIG. 52 illustrates a screwdriver 801. The screwdriver 801includes a motor 450 powered by a battery 430, the motor driving anoutput spindle 260. The output spindle 260 is configured to hold ahexagonal bit, such as a screwdriver or drill bit. A circuit board 861is adjacent to the battery 430 and is directly connected to socket 420(i.e., no connecting wires). Accordingly, power is provided directly tothe circuit board 461 through the socket 420.

FIG. 54 illustrates another screwdriver 802. The screwdriver 802includes motor 450 powered by battery 430, and output spindle 260 drivenby the motor 450. A transmission 870 is disposed between the motor 450and the output spindle 260. A circuit board 862 is adjacent to thebattery 430 and is directly connected to socket 420 so that power isprovided directly to the circuit board 862 through the socket 420. Thecircuit board 862 is connected to the battery 430 by one or moreconnectors, such as connector 812, shown in FIG. 56 . The connector 812provides an electrical connection between the circuit board 862 and thebattery 430. The connector 812 is conductive and may be made of metal.Connections are provided between the circuit board 862 and positive andnegative terminals of the battery 430. Though not shown, similarconnectors may be used to provide an electrical connection in theembodiment of FIG. 52 .

FIG. 57 illustrates another screwdriver 803. The screwdriver 803includes motor 450 powered by battery 430, and output spindle 260 drivenby the motor 450. A transmission 870 is disposed between the motor 450and the output spindle 260. The screwdriver 803 also includes a light855. The light 855 is actuated by virtue of a switch 856. The light 855and switch 856 can be connected to the circuit board 863, and thus powerfrom the battery 430, by conventional means such as wires 170.Alternatively, or in combination, one or both of the light 855 andswitch 856 may be connected to the circuit board 863 directly through acircuit board or by other structures, as taught by this specification.

The circuit board 863 is adjacent to the battery 430 and is directlyconnected to socket 420 so that power is provided directly to thecircuit board 863 through the socket 420. The circuit board 863 isconnected to the battery 430 by one or more connectors, such asconnector 813, shown in FIG. 59 . The connector 813 provides anelectrical connection between the circuit board 863 and the battery 430.As with previous connectors, the connector 813 is conductive and may bemade of metal. Connections are provided between the circuit board 863and positive and negative terminals of the battery 430.

FIG. 60 illustrates another screwdriver 804. The screwdriver 804likewise includes motor 450 powered by battery 430, and output spindle260 driven by the motor 450. A transmission 870 is disposed between themotor 450 and the output spindle 260. The screwdriver 804 also includesa light 855. The light 855 is activated via switch 857. The light 855and switch 857 can be connected to the circuit board 864, and thus powerfrom the battery 430, by conventional means such as wires 170.Alternatively, or in combination, one or both of the light 855 andswitch 857 may be connected to the circuit board 864 directly through acircuit board or by other structures, as taught by this specification.

The circuit board 864 is adjacent to the battery 430 and is directlyconnected to socket 420 so that power is provided directly to thecircuit board 864 through the socket 420. The circuit board 864 isconnected to the battery 430 by one or more connectors, such asconnector 814, shown in FIG. 59 . The connector 814 provides anelectrical connection between the circuit board 864 and the battery 430.As with previous connectors, the connector 814 is conductive and may bemade of metal. Connections are provided between the circuit board 864and positive and negative terminals of the battery 430.

FIGS. 63-68 illustrate a structure for providing power into the toolsdiscussed in the specification, such as the hand vacs and screwdrivers.FIGS. 63 and 64 illustrate a structure using wires. FIGS. 65-68illustrate a method of direct connection to a circuit board.

FIGS. 63 and 64 illustrate a socket structure 900 for providing powerinto a tool. This socket structure 900 may be used for the socket 420,shown in the various illustrations if wires are being used. The socketstructure 900 includes a housing 910. Power is provided into the socketthrough terminals 901 and 902. Terminal 901 may be a positive terminaland terminal 902 may be a negative terminal. The terminals may also bereversed. As shown, the terminal 901 is connected to a metal conductor913 with an end 903. The end 903 has a hole 911. The end 903 and hole911 are configured such that a wire can be connected and the wire iselectrically connected to the positive terminal 901. The terminal 902 isconnected to a metal conductor 914 with an end 904. The end 904 has ahole 912. The end 904 and hole 912 are configured such that a wire canbe connected and the wire is electrically connected to the negativeterminal 902. The socket structure 900 also includes a metal ground tab905.

FIGS. 65-68 illustrate a socket structure 950 for providing power to thehand vacs or screwdrivers. The socket structure 950 is configured fordirect connection to a circuit board. It may be used for the socket 420and provides for direct connection to a circuit board. For example, thesocket structure 950 may be used in the embodiment of FIG. 52 so thatthe circuit board 861 is plugged directly into the socket.

The socket structure 950 includes a housing 951. Power is provided intothe socket through terminals 961 and 962. Terminal 961 may be a positiveterminal and terminal 962 may be a negative terminal. The terminals mayalso have the reverse locations. As shown, the terminal 961 is connectedto a metal conductor 963 with a projection 967. The projection isconfigured to engage with the circuit board 980. The projection 967 maybe soldered to the circuit board 980 or electrical connection may bemade by simple contact or other means.

Terminal 962 is connected to a metal conductor 964 with a projection968. The projection is configured to engage with the circuit board 980.The projection 968 may be soldered to the circuit board 980 orelectrical connection may be made by simple contact or other means. Thesocket structure 950 also includes a metal ground tab 965.

As shown in FIGS. 65-68 , the socket structure 950, particularly thehousing 951, includes a slot 970 for receiving the circuit board 980.Accordingly, the circuit board 980 may be slid into an appropriateposition so that it can engage the projections 967 and 968.

In this manner, power is provided directly from the socket 950 to thecircuit board 980. As noted above, the socket 950 may be used as thesocket 420 in the various embodiments shown in this disclosure.Additionally, the circuit boards shown as plugging into the sockets maybe used. For example, the circuit board 861 shown in FIGS. 52 and 52 maybe used in the position of circuit board 980. Also, this socket andcircuit board arrangement may be used for the various products shown inthe various embodiments to provide power directly from the socket to thecircuit board and, therefore, the product.

FIGS. 69 and 70 illustrate a prior art plug configuration.

FIGS. 71 and 72 illustrate an embodiment of a new plug configuration.FIG. 71 is a perspective view of the side of the socket structure 950opposite that shown in FIGS. 63 and 64 . The side shown in FIG. 71 is acharger receiving side, as it receives recessed pins 971 and 972 fromthe charger plug 975 shown in FIG. 72 .

FIG. 72 illustrates a charger plug 975. The charger plug 975 providespower into the socket 950 it may receive power from a traditional wallpower outlet, such as a 120V AC outlet (conventional, not shown). Thecharger plug includes two pins 971 and 972. The pin 971 engages terminal961 and pin 972 engages terminal 962. Pin 971 is a positive pin and pin972 is a negative pin, though these could be reversed if the terminalsare reversed. Additionally, the charger plug 975 includes a groundconnection 976 which engages a ground connection 966 on the socket 950,which is connected to the ground tab 965. As shown, the plug 975 and thesocket 950 have corresponding lockout features 977 and 978. In this way,power is provided to the socket 950. The socket 900 of FIGS. 63 and 64may have a similar configuration on a charger receiving side so that thesocket 900 may similarly receive charger plug 975.

It will be appreciated that features of the various embodiments may becombined where compatible, and such combinations of various features iscontemplated by this disclosure.

While the invention has been described by way of exemplary embodiments,it is understood that the words which have been used herein are words ofdescription, rather than words of limitation. Changes may be made withinthe purview of the appended claims, without departing from the scope andspirit of the invention in its broader aspects.

What is claimed is:
 1. A hand-held tool, comprising: a housing, thehousing including a handle; a motor assembly including a motor; a firstbattery assembly; a circuit board; and a actuator configured toselectively turn on the motor; wherein the first battery assemblycomprises a first battery cell with a first battery cell positiveterminal and a first battery cell negative terminal; wherein the firstbattery assembly further comprises a first rigid conductive electricalconnector having a first end fixed to the first battery cell positiveterminal and a second end fixed to the circuit board and a second rigidconductive electrical connector having a first end fixed to the firstbattery cell negative terminal and a second end fixed to the circuitboard.
 2. The hand-held tool of claim 1, wherein the first battery cellcomprises a longitudinal axis which is disposed at an angle with respectto the circuit board, the angle being between 10 degrees and 90 degrees.3. The hand-held tool of claim 1, wherein at least one of the firstrigid conductive electrical connector and the second rigid conductiveelectrical connector runs parallel to a longitudinal axis of the firstbattery cell.
 4. The hand-held tool of claim 1, wherein the first rigidconductive electrical connector and the second rigid conductiveelectrical connector are a stamped metal connectors.
 5. The hand-heldtool of claim 1, wherein the first rigid conductive electrical connectoris soldered to the circuit board; and wherein the second rigidconductive electrical connector is soldered to the circuit board.
 6. Thehand-held tool of claim 1, wherein the first rigid conductive electricalconnector is fixed to the circuit board by a tulip connector; andwherein the second rigid conductive electrical connector is fixed to thecircuit board by a tulip connector.
 7. The hand-held tool of claim 1,wherein the hand-held tool comprises a hand-held vacuum cleaner.
 8. Thehand-held tool of claim 1, wherein the hand-held tool comprises a powertool configured to hold and drive a bit.
 9. The hand-held tool of claim1, further comprising a second battery assembly comprising a secondbattery cell.
 10. The hand-held tool of claim 9, wherein the secondbattery assembly further comprises a second battery cell positiveterminal and a second battery cell negative terminal.
 11. The hand-heldtool of claim 10, wherein the second battery assembly further comprisesa third rigid conductive electrical connector having a first end fixedto the second battery cell positive terminal and a second end fixed tothe circuit board and a fourth rigid conductive electrical connectorhaving a first end fixed to the second battery cell negative terminaland a second end fixed to the circuit board.
 12. The hand-held tool ofclaim 9, wherein the motor has a longitudinal axis and the first batterycell is disposed parallel to the longitudinal axis of the motor.
 13. Thehand-held tool of claim 9, wherein the second battery cell is disposedparallel to a longitudinal axis of the motor.
 14. The hand-held tool ofclaim 9, wherein the motor comprises a rotatable motor output shaft; andwherein the motor is connected to the circuit board by motor rigidconductive electrical connectors.
 15. The hand-held tool of claim 1,wherein the first battery cell is adjacent to the motor.
 16. Thehand-held tool of claim 9, wherein the first battery cell is disposed ona first side of the motor; and wherein the second battery cell isdisposed on a second side of the motor opposite the first side of themotor.
 17. The hand-held tool of claim 1, wherein the first battery cellis configured to be charged by a battery charger that includes a primarycell monitor.
 18. The hand-held tool of claim 17, wherein the firstbattery cell is configured to be charged by a battery charger thatincludes a secondary cell monitor.
 19. The hand-held tool of claim 17,wherein the first battery cell is configured to be charged by a batterycharger that includes an independent charge shut-off.